DE102016124154A1 - A method and arrangement for molding components having an internal passage formed therein - Google Patents

Abstract

What is provided is a method (1500) of forming a component (80) having an internal passageway (82) formed therein. The method includes positioning (1502) a sheathed core (310) with respect to a mold (300). The sheathed core has a hollow structure (320) formed at least partially by an additive manufacturing process and an inner core (324) disposed within the hollow structure. The method further includes introducing (1504) a component material (78) in a molten state into a cavity (304) of the mold and cooling (1506) the component material in the cavity to form the component. The inner core is positioned to define the internal passageway in the component.

Description

BACKGROUND

 The field of description relates generally to components having an internal passageway formed therein, and more particularly to forming such internal passageways by cores defining at least a large ratio of length to diameter, substantially non-linear shape, and / or complex cross-sectional perimeter ,

 Some components require formation of an internal passage in their interior, for example, to perform a targeted function. For example, but not limited to, some components, e.g. Hot gas path components of gas turbines exposed to high temperatures. At least in some such components, internal passages are formed therein to receive a flow of cooling fluid so that the components can better withstand the high temperatures. In another example, but not limiting, some components are subject to friction at a point of contact with another component. At least in some such components, internal passages are formed therein to receive a flow of lubricant to effect a reduction in friction.

 At least some known components having an internal passage formed therein are formed in a mold, with a core made of a ceramic material extending within the mold cavity at a location selected for internal passage. After a molten metal alloy is introduced into the mold cavity around the ceramic core and cooled to form the component, the ceramic core, e.g. by chemical leaching, removed to form the internal passageway. However, at least some known ceramic cores are fragile, with the result that the manufacture of the cores is costly and difficult to handle without damage. By way of non-limiting example, as the ratio of length to diameter (L / d) of the ceramic core increases, so does the risk that the core will crack or break during handling and / or use in the manufacture of a component.

 The risk of cracking or breaking at least part of such ceramic cores increases even further with non-linearity of the ceramic cores. For example, a substantially linear ceramic core with a direction of gravity can be oriented so that the core supports its own weight in a columnar compression. In contrast, when a substantially nonlinear core is kept floating within a mold cavity, the weight of the core subjects a portion of the ceramic core to stress, further increasing the risk of cracking or breaking of the ceramic core. Additionally or alternatively, at least some of such cores are themselves produced by casting the ceramic material into a core casting mold, and the fabrication of at least some substantially nonlinear ceramic cores is difficult because of a problem of providing suitable additions and design angles for disengaging the non-linear ceramic core from the core casting mold. Thus, use of such known ceramic cores to form internal passageways having substantial nonlinearity, particularly, but not limited to, is limited with an increase in the L / d ratio of the passageway.

 In addition, the risk of cracking or breaking at least a part of such ceramic cores increases with an increase in the complexity of a cross section of the ceramic core. By way of non-limiting example, a non-smooth cross-sectional dimension introduces stress concentrations into the ceramic core that increase the risk of localized cracking. Thus, while a heat transfer performance of an internal cooling duct could be improved, for example, by a cross-section that increases a wetted perimeter of the passage for a given cross-sectional area, use of such known ceramic cores to form such a cross-section will be particularly, but not limited to , therefore limited with an increase in the L / d ratios of the passageway.

Alternatively or additionally, at least some known components having an internal passage formed therein are initially formed without the internal passage, and the internal passage is formed in a subsequent process. For example, at least some known internal passageways are formed by drilling the passage, for example, but without limitation, into the component by means of an electrochemical drilling process. However, at least some such methods are relatively time consuming and costly. Besides, they are at least some such methods fail to produce a non-linearity and / or cross-sectional extent of internal passage required for designs of certain components, particularly, but not limited to, with an increase in the L / d ratio of the port channel.

SUMMARY

 In one aspect, there is provided a method of forming a component having an internal passage formed therein. The method includes positioning a sheathed core with respect to a casting mold. The sheathed core has a hollow structure formed at least partially by an additive manufacturing process and an inner core disposed within the hollow structure. The method further includes introducing a component material in a molten state into a cavity of the mold and cooling the component material in the cavity to form the component. The inner core forms the internal passage in the component.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core involves positioning the sheathed core having the hollow structure formed using at least one direct metal laser melt (DMLM) method of direct metal laser sintering (Direct Metal Laser) Sintering, DMLS) method and / or a selective laser sintering (Selective Laser Sintering, SLS) method is formed.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the hollow structure formed of a first material at least partially defined by at least one nickel-base superalloy, a cobalt-based superalloy, an iron-based alloy, a titanium-based alloy and / or a platinum-based superalloy is absorbable.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the inner core formed of at least one of silica, alumina, and / or mullite.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 25.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 60.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 70.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 80.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the inner core defining a ratio of a length to an end separation distance of at least about 1.2.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the inner core defining a ratio of a length to an end separation distance of at least about 3.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the inner core defining a ratio of a length to an end separation distance of at least about 6.

In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core that includes at least a portion of the inner core defining a cross section, the cross section defining a ratio of a perimeter squared to an area of at least about 40.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having at least a portion of the inner core defining a cross section, the cross section being a ratio of a perimeter squared to a surface defined by at least about 80.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the hollow structure defining a plurality of substantially linear segments connected in series.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having the hollow structure defining a plurality of substantially linear segments connected in series with a plurality of arcuate segments.

 In any embodiment of the method, it may be advantageous that the positioning of the sheathed core includes positioning the sheathed core having at least a portion of the hollow structure defining a substantially helical shape.

 In another aspect, there is provided a mold assembly for use in molding a component having an internal passage formed therein. The mold assembly includes a mold defining therein a mold cavity and a sheathed core positioned with respect to the mold. The sheathed core has a hollow structure that is at least partially formed by an additive manufacturing process. The sheathed core further includes an inner core disposed within the hollow structure and positioned to form the internal passageway in the component when a component material in a molten state is introduced into the cavity and cooled about the component to shape.

 In any embodiment of the mold assembly, it may be advantageous for the hollow structure to be formed of a first material that is at least partially absorbable by at least one nickel-base superalloy, a cobalt-based superalloy, an iron-based alloy, a titanium-based alloy, and / or a platinum-based superalloy.

 In any embodiment of the mold assembly, it may be advantageous for the inner core to be formed of at least one of silica, alumina and mullite.

 In any embodiment of the mold assembly, it may be advantageous for the inner core to define a ratio of length to diameter of at least about 25.

 In any embodiment of the mold assembly, it may be advantageous for the inner core to define a ratio of length to diameter of at least about 60.

 In any embodiment of the mold assembly, it may be advantageous for the inner core to define a ratio of length to diameter of at least about 70.

 In any embodiment of the mold assembly, it may be advantageous for the inner core to define a ratio of length to diameter of at least about 80.

 In any embodiment of the mold assembly, it may be advantageous for the inner core to define a ratio of a length to an end separation distance of at least about 1.2.

 In any embodiment of the mold assembly, it may be advantageous for the inner core to define a ratio of a length to an end separation distance of at least about 3.

In any embodiment of the mold assembly, it may be advantageous for the inner core to define a ratio of a length to an end separation distance of at least about 6.

 In any embodiment of the mold assembly, it may be advantageous for at least a portion of the inner core to define a cross-section, the cross-section defining a ratio of a perimeter squared to an area of at least about 40.

 In any embodiment of the mold assembly, it may be advantageous for at least a portion of the inner core to define a cross-section, the cross-section defining a ratio of a perimeter squared to an area of at least about 80.

 In any embodiment of the mold assembly, it may be advantageous for the hollow structure to define a plurality of substantially linear segments connected in series.

 In any embodiment of the mold assembly, it may be advantageous for the hollow structure to define a plurality of substantially linear segments connected in series with a plurality of curved segments.

 In any embodiment of the mold assembly, it may be advantageous for at least a portion of the hollow structure to define a substantially spiral shape.

DRAWINGS

1 shows a block diagram of an exemplary rotating machine;

2 shows in a schematic perspective view of an exemplary component for use in the in 1 shown rotating machine;

3 shows in a schematic perspective view of an exemplary mold assembly for producing the in 2 wherein the mold assembly has a sheathed core positioned with respect to a mold;

4 illustrated schematically along the in 3 4-4 show a cross-section of an exemplary jacketed core for use in the present invention 3 shown mold assembly;

5 shows in a schematic perspective view a portion of another exemplary component for use in the in 1 shown rotating machine, wherein the component has an internal passage;

6 shows in a schematic perspective view a portion of another exemplary sheathed core for use in the present invention 3 shown mold assembly to form the component, as shown in 5 having features of the inner channel;

7 FIG. 3 shows a schematic perspective view of three additional exemplary jacketed cores for use in FIG 3 shown mold assembly;

8th FIG. 12 is a schematic sectional view of six additional exemplary jacketed cores for use in the present invention. FIG 3 shown mold assembly;

9 shows in a schematic perspective view a portion of another exemplary component for use in the in 1 shown rotating machine, wherein the component has an internal passage;

10 shows in a schematic perspective view a portion of another exemplary sheathed core for use in the present invention 3 shown mold assembly to the in 9 form component shown;

11 shows in a schematic perspective view a portion of another exemplary component for use in the in 1 shown rotating machine, wherein the component has an internal passage with a contoured cross-section;

12 shows a schematic perspective cutaway view of another exemplary sheathed core for use in the present invention 3 shown mold assembly to form the component, the in 11 having shown internal passage;

13 shows in a schematic perspective view a portion of another exemplary component for use in the in 1 shown rotating machine, wherein the component has an internal passage;

14 shows in a schematic perspective view a portion of another exemplary sheathed core for use in the present invention 3 shown mold assembly to form the component having features of the inner channel, as in 13 shown;

15 FIG. 12 shows a flowchart of an exemplary method of forming a component having an internal passage formed therein, for example, a component for use in FIG 1 shown rotating machine; and

16 shows a continuation of the flowchart of 15 ,

DETAILED DESCRIPTION

 In the following description and in the claims, reference will be made to a number of terms whose meanings are defined as follows.

 The singular forms of indefinite and definite articles also include plurals, unless the context presupposes otherwise.

 "Optional" means that the event or condition described below may or may not occur, and that the description includes both cases in which the event occurs and those in which it does not occur.

 Approximate language as used throughout the specification and claims may be used to modify a quantitative representation that could reasonably deviate without causing a change in the fundamental function to which it refers. Accordingly, a value modified by one or more terms such as "about," "about," and "substantially" is not intended to be limited to the specified value. In at least some instances, the approximate language may correspond to the accuracy of an instrument used to capture the value. In the present and throughout the description and claims, range limitations may be indicated. Such areas may be combined and / or interchanged and include all sub-areas contained therein unless otherwise specified in the context.

 The exemplary components and methods described herein eliminate at least some of the disadvantages associated with known devices and methods for molding a component having an internal passageway. The embodiments described herein provide a sheathed core that is positioned with respect to a mold. The sheathed core has a hollow structure and an inner core disposed within the hollow structure. The inner core extends inside the mold cavity to define a position of the internal passage within the component to be molded in the mold. The hollow structure is formed at least partially by means of an additive manufacturing process.

1 shows a schematic view of an exemplary rotating machine 10 containing components for which embodiments of the present description can be used. In the embodiment, the rotating machine is 10 a gas turbine, which has a suction section 12 , a compressor section 14 , the downstream of the suction section 12 is attached, a combustion chamber section 16 , the downstream of the compressor section 14 is mounted, a turbine section 18 , the downstream of the combustion chamber section 16 is attached, and an outlet section 20 , the downstream of the turbine section 18 is attached has. A substantially tubular housing 36 at least partially envelops the intake section 12 , the compressor section 14 , the combustion chamber section 16 , the turbine section 18 and / or the outlet section 20 , In modified embodiments, the rotating machine 10 any rotating machine for which components are suitable which, as described herein, are formed with internal passages. Although embodiments of the present description are described for purposes of illustration in the context of a rotating machine, it should also be understood that the embodiments described herein may be used in any context that utilizes a component that is properly shaped with an internal passageway formed therein ,

In the embodiment, the turbine section 18 over a rotor shaft 22 with the compressor section 14 connected. It should be noted that the term "connect" as used herein is not limited to an immediate mechanical, electrical and / or data-exchanging connection between components, but rather also an indirect mechanical, electrical and / or data-exchanging connection between a plurality Components may include.

During operation of the rotating machine 10 directs the intake section 12 Air in the direction of the compressor section 14 , The compressor section 14 gives the air by compression a higher pressure and a higher temperature. Special lends the rotor shaft 22 at least one circumferentially arranged row of compressor blades 40 connected to the rotor shaft 22 within the compressor section 14 are connected, rotational energy. In the embodiment, each row of compressor blades is 40 a circumferentially arranged row of compressor stator vanes 42 preceded by the housing 36 extend radially inward and the air flow into the compressor blades 40 to steer. The rotational energy of the compressor blades 40 increases a pressure and a temperature of the air. The compressor section 14 discharges the compressed air in the direction of the combustion chamber section 16 ,

In the combustion chamber section 16 The compressed air is mixed with fuel and ignited to produce combustion gases, which are in the direction of the turbine section 18 be directed. More specifically, the combustor section 16 at least one burner 24 in which a fuel, for example natural gas and / or diesel oil, is injected into the air stream and in which the fuel / air mixture is ignited to produce hot combustion gases, which are in the direction of the turbine section 18 be directed.

The turbine section 18 converts the thermal energy originating from the combustion gas stream into mechanical rotational energy. More specifically, the combustion gases impart at least one circumferentially arranged row of blades 70 connected to the rotor shaft 22 within the turbine section 18 are connected, rotational energy. In the embodiment, each row of rotor blades 70 a circumferentially array of turbine stator vanes 72 preceded by the housing 36 extend radially inward and the combustion gases into the blades 70 to steer. The rotor shaft 22 For example, but not limited to, a load (not shown) may be connected to an electric generator and / or a mechanical drive application. The depressurized combustion gases flow from the turbine section 18 downstream into the outlet section 20 , Components of the rotating machine 10 are as components 80 designated. The components 80 that are near a path of the combustion gases are during operation of the rotating machine 10 exposed to high temperatures. Additionally or alternatively, the components include 80 any component suitably shaped with an internal passage formed therein.

2 shows a schematic perspective view of an exemplary component 80 suitable for use in the (in 1 shown) rotary machine 10 is illustrated. The component 80 has at least one internal passage formed therein 82 on. For example, the internal passage 82 during operation of the rotating machine 10 a cooling fluid is supplied to the component 80 maintain below a temperature of the hot combustion gases. Although only an internal passage 82 It should be understood that the component 80 any suitable number of internal passes 82 which are formed as described herein.

The component 80 is made of a component material 78 educated. In the embodiment, the component material is 78 a suitable nickel base superalloy. In modified embodiments, the component material 78 at least one cobalt-based superalloy, an iron-based alloy, a titanium-based alloy and / or a platinum-based superalloy. In other modified embodiments, the component material 78 Any suitable material that allows the component 80 to shape as described here.

In the embodiment, the component is 80 a rotor blade 70 or a stator vane 72 , In modified embodiments, the component 80 another suitable component of the rotating machine 10 which, as described herein, can be formed with an internal passageway. In still other embodiments, the component is 80 an arbitrary component intended for any suitable application, suitably formed with an internal passage formed therein.

In the embodiment, the rotor blade 70 or alternatively the stator vane 72 , a printed page 74 and an opposite suction side 76 on. The print side 74 and the suction side 76 each extend from a leading edge 84 to an opposite trailing edge 86 , In addition, the rotor blade extends 70 or alternatively the stator vane 72 , from a foot end 88 to an opposite tip end 90 that a blade length 96 Are defined. In modified embodiments, the rotor blade 70 or alternatively the stator vane 72 , any suitable configuration that may be formed with an internal passage as described herein.

In specific embodiments, the blade length is 96 at least about 25.4 centimeters (cm) (10 inches). In addition, the blade length is 96 at least about 50.8 cm (20 inches) in some embodiments. In specific embodiments, the blade length is 96 in a range of about 61 cm (24 inches) to about 101.6 cm (40 inches). In modified embodiments, the blade length is 96 less than about 25.4 cm (10 inches). For example, the blade length is 96 in some embodiments, in a range of about 1 inch to about 10 inches. In other modified embodiments, the blade length 96 greater than about 101.6 cm (40 inches).

In the embodiment, the internal passage extends 82 starting from the foot end 88 to the top end 90 , In alternative embodiments, the internal passage extends 82 inside the component 80 in any suitable manner and to any suitable extent, that forms the internal passageway 82 allow, as described here. In specific embodiments, the internal passage is 82 not linear. For example, the component 80 along an axis 89 that is between the foot end 88 and the top end 90 is defined, formed with a predefined rotation, and the internal passage 82 has a curved shape that is complementary to the axial rotation. In some embodiments, the internal passage is 82 over the length of the internal passage 82 away with a substantially constant distance 94 from the pressure side 74 arranged. Alternatively or additionally, a tendon of the component runs 80 between the foot end 88 and the top end 90 sloping, and the internal passageway 82 extends complementary to the slope non-linear, allowing the internal passage 82 along the length of the internal passage 82 with a substantially constant distance 92 from the trailing edge 86 is arranged. In modified embodiments, the internal passageway 82 a non-linear shape corresponding to any suitable outline of the component 80 is complementary. In other modified embodiments, the internal passageway 82 to an outline of the component 80 not linear and anything but complementary. In some embodiments, the internal pass allows 82 having a non-linear shape, satisfying a preselected cooling criterion for the component 80 , In alternative embodiments, the internal passage extends 82 linear.

In some embodiments, the internal passageway 82 a substantially circular cross section. In modified embodiments, the internal passageway 82 a substantially oval cross section. In other modified embodiments, the internal passage 82 an arbitrarily designed shaped cross-section, which forms a shape of the internal passage 82 permitted as described here. In addition, a shape of the cross section of the internal passage 82 in some embodiments, over the length of the internal passage 82 essentially constant. In modified embodiments, the shape of the cross section of the internal passage varies 82 over the length of the internal passage 82 in any suitable manner, shaping the internal passageway 82 permitted as described here.

3 shows a schematic perspective view of a mold assembly 301 for making the (in 2 shown) component 80 , The mold assembly 301 contains a sheathed core 310 that is in relation to a mold 300 is positioned. 4 schematically illustrates a cross section of the sheathed core 310 along the in 3 shown section line 4-4. With reference to 2 - 4 defines an inner wall 302 the mold 300 a mold cavity 304 , The inner wall 302 defines a shape that corresponds to an external shape of the component 80 matches, so the component material 78 in a molten state into the mold cavity 304 can be introduced and cooled to the component 80 to build. Although the component 80 in the embodiment, the rotor blade 70 or alternatively the stator vane 72 , is, it is reminded that the component 80 in modified embodiments, is any component that may be suitably formed with an internal passageway formed therein, as described herein.

The sheathed core 310 is in relation to the mold 300 positioned so that a section 315 of the sheathed core 310 inside the mold cavity 304 extends. The sheathed core 310 has a hollow structure 320 made of a first material 322 is formed, and an inner core 324 on that inside the hollow structure 320 is arranged, and that of an inner core material 326 is formed. The inner core 324 is designed to be a form of internal passage 82 to define, and the inner core 324 of the section 315 of the sheathed core 310 Standing inside the mold cavity 304 positioned defines a position of the internal passage 82 inside the component 80 ,

The hollow structure 320 has an outer wall 380 on that the inner core 324 over the length of the inner core 324 essentially enveloped. An inner section 360 the hollow structure 320 is in relation to the outer wall 380 arranged inside, leaving the inner core 324 through the inner section 360 the hollow structure 320 is designed to be complementary. In specific embodiments, the hollow structure defines 320 a substantially tubular shape. For example, but without wishing to be limited, the hollow structure is 320 is formed as a tube suitably arranged as needed in a non-linear shape, for example, a curved or angled shape, to a selected non-linear shape of the inner core 324 , and thus the internal passage 82 , define. In modified embodiments, the hollow structure defines 320 any suitable shape that suits the inner core 324 allowed, a shape of the internal passage 82 to define how it is described here.

In the embodiment, the hollow structure 320 a wall thickness 328 which is smaller than a characteristic width 330 of the inner core 324 , The characteristic width 330 is defined herein as the diameter of a circle having the same cross-sectional area as the inner core 324 , In modified embodiments, the hollow structure 320 a wall thickness 328 which is anything but smaller than the characteristic width 330 is. In the in 3 and 4 shown embodiment is a shape of a cross section of the inner core 324 circular. Alternatively, the shape of the cross section of the inner core corresponds 324 any suitable cross section of the internal passage 82 It's the internal passageway 82 allows to fulfill the function described here.

The mold 300 is made of a mold material 306. educated. In the embodiment, the mold material is 306. a refractory ceramic material selected to withstand a high temperature environment, which is the molten state of the component material 78 is assigned, which is used to the component 80 to build. In modified embodiments, the mold material 306. Any suitable material that allows the component 80 to shape as described here. In addition, the mold 300 formed in the embodiment by a suitable lost wax process. For example, but not limited to, a suitable template material, eg wax, is injected into a suitable pattern die around a template (not shown) of the component 80 with the stencil repeated in a slurry of the casting material 306. is dipped, which is allowed to harden, leaving a shell of mold material 306. is formed, and wherein the shell is dewaxed and fired to form the mold 300 , In modified embodiments, the mold is 300 formed by any suitable method, that of the mold 300 allows to fulfill the function described here.

In specific embodiments, the sheathed core becomes 310 in terms of the mold 300 secured so that the sheathed core 310 in terms of the mold 300 during a process of formation of the component 80 remains stationary. For example, the sheathed core 310 secured, leaving a position of the sheathed core 310 during the introduction of the molten component material 78 into the mold cavity 304 , the sheathed core 310 surrounds, not changed. In some embodiments, the sheathed core is 310 directly with the mold 300 connected. For example, a tip section 312 of the sheathed core 310 in the embodiment in a tip section 314 the mold 300 wrapped tightly. Additionally or alternatively, a foot section 316 of the sheathed core 310 in a foot section 318 the mold 300 rigidly wrapped, the top section 314 opposite. For example, but without wishing to be limited, the casting mold becomes 300 As described above, formed by lost wax casting, and the sheathed core 310 is securely connected to the appropriate pattern die, so that the tip section 312 and the foot section 316 extend out of the pattern die while the section 315 extends within a cavity of the die. The stencil material is placed in the die around the sheathed core 310 injected, so that the section 315 extends within the template. The lost wax casting causes the die 300 the top section 312 and / or the foot section 316 envelops. Additionally or alternatively, the sheathed core 310 in terms of the mold 300 secured in any other suitable manner, which allows the position of the sheathed core 310 in terms of the mold 300 during an operation for forming the component 80 remains stationary.

The first material 322 is selected to be at least partially through the molten component material 78 to be absorbable. In specific embodiments, the component material is 78 an alloy, and the first material 322 is at least one base material of the alloy. For example, the component material 78 in the embodiment, a nickel base superalloy, and the first material 322 is essentially nickel, so the first material 322 through the component material 78 is essentially absorbable when the component material 78 in the molten state into the mold cavity 304 is introduced. In modified embodiments, the component material 78 Any suitable alloy, and the first material 322 is at least one material that is at least partially absorbable by the molten alloy. For example, the component material 78 a cobalt-based superalloy, and the first material 322 is essentially cobalt. In another example, the component material 78 an iron-based alloy, and the first material 322 is essentially iron. In another example, the component material 78 a titanium-based alloy, and the first material 322 is essentially titanium. In another example, the component material 78 a platinum-based alloy, and the first material 322 is essentially platinum.

In specific embodiments, the wall thickness 328 sufficiently thin, so that the first material 322 of the section 315 of the sheathed core 310 , ie the section that is inside the mold cavity 304 extends, essentially through the component material 78 is absorbed when the component material 78 in the molten state into the mold cavity 304 is introduced. For example, the first material 322 in some such embodiments, by the component material 78 essentially absorbed, so no separate limit the hollow structure 320 from the component material 78 delimits after the component material 78 is cooled. In addition, the first material 322 is substantially absorbed in some such embodiments, so that after the component material 78 Chilled, the first material 322 in the component material 78 is distributed substantially evenly. For example, a concentration of the first material 322 near the inner core 324 not detectable higher than a concentration of the first material 322 elsewhere in the interior of the component 80 , For example, and without wanting to be limited, this is the first material 322 Nickel, and the component material 78 is a nickel-base superalloy, and it stays near the inner core 324 no detectable higher nickel concentration after the component material 78 is cooled, with the result that the distribution of nickel in the entire nickel-base superalloy of the formed component 80 is substantially homogeneous.

In modified embodiments, the wall thickness 328 suitably selected so that the first material 322 anything but essentially the component material 78 is absorbed. For example, the first material 322 in some embodiments, after the component material 78 is anything but substantially uniform in the component material 78 distributed. For example, a concentration of the first material 322 near the inner core 324 significantly higher than a concentration of the first material 322 elsewhere in the interior of the component 80 , In some such embodiments, the first material becomes 322 through the component material 78 partially absorbed, leaving a separate boundary to the hollow structure 320 from the component material 78 delimits after the component material 78 is cooled. In addition, the first material 322 in some such embodiments, by the component material 78 partially absorbed, leaving at least a portion of the hollow structure 320 near the inner core 324 remains intact after the component material 78 is cooled.

In the embodiment, the inner core material is 326 a refractory ceramic material selected to withstand a high temperature environment, which is the molten state of the component material 78 is assigned, which is used to the component 80 to build. By way of non-limiting example, however, the inner core material includes 326 at least one of silica, alumina and mullite. In addition, the inner core material 326 in the embodiment, selectively from the component 80 Removable to the internal passage 82 to build. For example, but without wishing to be limited, the inner core material is 326 from the component 80 removable by a suitable method, which is the component material 78 does not substantially wear, for example but not limited to, a suitable chemical leaching process. In specific embodiments, the inner core material is 326 based on compatibility with and / or removability from the component material 78 selected. In modified embodiments, the inner core material 326 Any suitable material that allows the component 80 to shape as described here.

In some embodiments, the sheathed core becomes 310 by filling the hollow structure 320 with the inner core material 326 educated. For example, but without wishing to be limited, the inner core material becomes 326 as a mud in the hollow structure 320 injected, and the inner core material 326 is in the hollow structure 320 dried around the sheathed core 310 to build. In addition, the inner core becomes 324 in certain embodiments through the hollow structure 320 structurally significantly reinforced, which reduces potential problems involved in the manufacture, handling and use of an unreinforced inner core 324 for the molding of the component 80 would occur in some embodiments. For example, the inner core 324 In some embodiments, a relatively brittle ceramic material which is subject to a relatively high risk of breakage, cracking and / or other damage. Therefore, the training and transport of the sheathed core represents 310 in some such embodiments as compared to using an uncovered inner core 324 a much lower risk of damage to the inner core 324 Likewise, forming a suitable template around the sheathed core 310 For the lost wax casting of the mold 300 by, for example, injecting a wax stencil material into a pattern die around the sheathed core 310 , is to be used in some such embodiments as compared to using an unjacketed inner core 324 a much lower risk of damaging the inner core 324 Consequently, using the covered core reduces 310 in some embodiments, in the preparation of a useful component 80 containing the internal passage formed therein 82 when compared to the same steps, if using an uncovered inner core 324 instead of the sheathed core 310 Running a risk of failure is essential. Thus, the sheathed core allows 310 To achieve advantages, the positioning of the inner core 324 in terms of the mold 300 to the internal passage 82 to form, while problems associated with the breakage sensitivity of the inner core 324 be reduced or eliminated. In modified embodiments, the hollow structure reinforces 320 the inner core 324 structurally not essential.

For example, the characteristic width is 330 of the inner core in certain embodiments, such as, but not limited to, embodiments in which the component 80 the rotor blade 70 is 324 in a range of about 0.050 cm (0.020 inches) to about 1.016 cm (0.400 inches), and the wall thickness 328 the hollow structure 320 is selected to be in the range of about 0.013 cm (0.005 inches) to about 0.254 cm (0.100 inches). More specific is the characteristic width 330 in some such embodiments ranging from about 0.102 cm (0.040 inches) to about 0.508 cm (0.200 inches), and the wall thickness 328 is selected to be in the range of about 0.013 cm (0.005 inches) to about 0.038 cm (0.015 inches). In another example, the characteristic width is 330 of the inner core 324 in some embodiments, such as, but not limited to, embodiments in which the component 80 a stationary component is, for example but not limited to, the stator vane 72 greater than about 1.016 cm (0.400 inches), and / or the wall thickness 328 is selected to be greater than about 0.254 cm (0.100 inches). In modified embodiments, the characteristic width 330 any suitable value, that of the resulting internal passage 82 allowed to fulfill its intended function, and the wall thickness 328 is selected to have any suitable value that matches the sheathed core 310 allows to fulfill the function described here.

5 shows in a schematic perspective view a portion of another exemplary component 80 that the internal passage 82 having. 6 shows in a schematic perspective view of the section 315 another exemplary encased core 310 , which in connection with the (in 3 shown) casting mold 300 can be used to in the 5 shown component 80 to build. In the embodiment, the component is 80 one of the blades 70 , In modified embodiments, the component 80 another suitable component of the rotating machine 10 which, as described herein, can be formed with an internal passageway. In still other embodiments, the component is 80 an arbitrary component intended for any suitable application, suitably formed with an internal passage formed therein.

With reference to 5 and 6 has the rotor blade 70 as discussed above, the print side 74 and the opposite suction side 76 up, each one from the foot end 88 to the opposite tip end 90 , bringing the blade length 96 is defined, and from the leading edge 84 to the opposite trailing edge 86 extend. In addition, the internal passage extends 82 as discussed above, starting from the foot end 88 to the top end 90 , In the embodiment, the rotor blade is running 70 from the foot end 88 to the top end 90 generally conical towards, and the rotor blade 70 is along the axis 89 that is between the foot end 88 and the top end 90 is defined, formed with a predefined rotation. The internal passage 82 is near the trailing edge 86 arranged and has a non-linear shape, which is adapted to the shape of the rotor blade 70 including conicity and axial rotation of the rotor blade 70 , correspond to.

The section 315 of the sheathed core has a non-linear shape, that of the non-linear shape of the internal passage 82 corresponds, so the inner core 324 the position of the internal passage 82 defined when the sheathed core 310 in terms of (in 3 shown) mold 300 is suitably positioned. The sheathed core 310 extends, including the hollow structure 320 and the inner core 324 , from a first end 362 that the foot end 88 the rotor blade 70 corresponds to an opposite second end 364 , the top end 90 the rotor blade 70 equivalent. An end separation distance 370 is as a length of a straight line between the first end 362 and the second end 364 Are defined. In the embodiment, the end separation distance is 370 due to the rotation and taper of the rotor blade 70 larger than the blade length 96 , In modified embodiments, the end separation distance is 370 less than or equal to the blade length 96 , For example, but without wishing to be limited, the sheathed core is 310 designed to the internal passage 82 to form that before reaching the top end 90 the component 80 ends.

Next is a length 372 of the sheathed core 310 as a path length along the section 315 from the first end 362 to the second end 364 Are defined. For example, defines the length 372 a stretch covered by a particle passing through the internal passageway 82 flows through the inner core 324 is trained. In the embodiment, the length is 372 due to the twist and taper of the sheathed core 310 greater than the end separation distance 370 ,

It is understood that the sheathed core in some embodiments 310 further sections 312 and 316 , such as in 3 shown to be a positioning of the sheathed core 310 in terms of the mold 300 perform. However, references are to the first end 362 , the second end 364 , the end separation distance 370 and the length 372 of the inner core 324 for purposes of this description as with respect to the section 315 defined to understand.

In addition, a ratio of a length to a diameter (L / d) for the inner core 324 as a ratio of length 372 to the (in 4 shown) characteristic width 330 Are defined. In addition, the ratio of a length to a diameter for the inner core 324 in the case of inner cores having variable cross sectional areas along their length, as a ratio of length 372 to the minimum characteristic width 330 Are defined.

For example, the blade length is 96 in some embodiments, at least about 25.4 cm (10 inches), the end separation distance 370 is at least about 26.45 cm (10.4 inches) in length 372 is at least about 27.6 cm (10.8 inches), and a ratio of a length to a diameter of the inner core 324 is in a range of about 25 to about 500. In another example, the blade length is 96 in some embodiments, at least about 55 cm (21.6 inches), the end separation distance 370 is at least about 56.5 cm (22.4 inches), the length 372 is at least about 61 cm (24 inches), and a ratio of a length to a diameter of the inner core 324 is in a range of about 60 to about 500. In another example, the blade length is 96 in some embodiments, at least about 61 cm (24 inches), the end separation distance 370 is at least about 63.5 cm (25 inches), the length 372 is at least about 75 cm (29.5 inches), and a ratio of a length to a diameter of the inner core 324 is in a range of about 70 to about 500. In another example, the blade length is 96 in some embodiments, at least about 101.6 cm (40 inches), the end separation distance 370 is at least about 105.7 cm (41.6 inches), the length 372 is at least about 127 cm (49.9 inches), and a ratio of a length to a diameter of the inner core 324 is in a range of about 80 to about 800. In modified embodiments, the blade length 96 , the end separation distance 370 , the length 372 and the ratio of a length to a diameter of the inner core 324 any suitable values that match the sheathed core 310 allow to fulfill the function described here.

In specific embodiments, using a (not shown) similarly non-linear, but uncoated, inner core having a length to diameter ratios of at least about 25, at least about 70, and / or at least about 80 would be such as, but not limited to to limit the inner cores described above 324 , have a relatively high risk in producing a reliably useful component 80 , inside which is the non-linear internal passage 82 is defined, to fail. For example, but not limited to, the weight of such uncoated, non-linear inner core tends to exposing at least a portion of the unjacketed core to stress, which increases the risk of cracking or breaking of the ceramic core prior to or during molding of the (in 3 shown) mold assembly 301 and / or the component 80 elevated. As discussed above, the inner core becomes 324 in some embodiments, through the hollow structure 320 However, structurally significantly reinforced, so that the sheathed core 310 in connection with connecting the inner core 324 with the mold 300 to the non-linear internal passage 82 allows to make advantages while problems related to the breakage sensitivity of the inner core 324 be reduced or eliminated. In modified embodiments, the hollow structure reinforces 320 the inner core 324 structurally not essential.

In some embodiments, the hollow structure becomes 320 before introduction of the inner core material 326 inside the hollow structure 320 to the sheathed core 310 to form, preformed, to a selected non-linear shape of the internal passage 82 to meet what a need, the inner core 324 form separately and / or machined, reduced or eliminated to a non-linear shape. More specifically, the hollow structure becomes 320 in some such embodiments at least partially formed using a suitable additive manufacturing process. For example, a computer design model becomes the hollow structure 320 between the first end 362 and the second end 364 cut into a series of thin, parallel layers. A computer numerical control (CNC) machine shears in accordance with the model layers from the first end 362 to the second end 364 successive layers of the first material 322 off to the hollow structure 320 to build. Three such illustrated layers are as layers 366 . 367 and 368 shown. In some embodiments, the successive layers of the first material become 322 using at least one direct metal laser melt (DMLM) process, a direct metal laser sintering (DMLS) process and / or a selective laser sintering (SLS) process. Additionally or alternatively, the successive layers of the first material 322 deposited by any suitable method that allows the hollow structure 320 to shape as described here. Next is the first material 322 further selected in some embodiments to be compatible with and / or enable the corresponding selected coating process.

In some embodiments, the formation allows the hollow structure 320 through an additive manufacturing process, the non-linear hollow structure 320 of structural complexity, accuracy and / or reproducibility, for example, not by machining a preformed straight pipe with respect to the preselected nonlinear shape of the hollow structure 320 achieve. Accordingly, the formation of the hollow structure allows 320 by an additive manufacturing process, the formation of the non-linear inner core 324 and thus the non-linear internal passage 82 with a correspondingly higher structural complexity, accuracy and / or reproducibility. Additionally or alternatively, the formation allows the hollow structure 320 during an additive manufacturing process, the formation of non-linear internal vias 82 that of the component 80 in a separate process, after initial molding of the component 80 in the mold 300 as discussed above, could not be reliably added.

7 shows in a schematic perspective view three additional embodiments of the sheathed core 310 for use in the (in 3 shown) mold assembly 301 , In each embodiment, the sheathed core becomes 310 designed to a selected non-linear shape of the internal passage 82 to comply, ie the hollow structure 320 is designed to be the inner core 324 inside the hollow structure 320 is arranged, the non-linear internal passage 82 inside the (in 2 shown) component 80 defines if the component 80 in the mold 300 is trained. In the first embodiment, the in 7 The left side shows the hollow structure 320 several substantially linear segments 374 which are connected in series, each adjacent pair being linear segments 374 in between a corresponding angle 376 Are defined. In correspondence is the inner core 324 designed to the internal passage 82 inside the component 80 as a series of linear segments that form at appropriate angles 376 united. In the second embodiment, in the middle of 7 is shown has the hollow structure 320 several substantially linear segments 374 on in series with multiple curved segments 378 are connected, each adjacent pair of segments 374 and or 378 in between a corresponding angle 376 forms. In correspondence is the inner core 324 designed to the internal passage 82 inside the component 80 as a series of linear and curved segments that form at appropriate angles 376 united. In the fourth embodiment, which is in 7 shown on the right defines the hollow structure 320 a substantially spiral shape 382 , In correspondence is the inner core 324 designed to the internal passage 82 inside the component 80 to impart a substantially spiral shape.

Although the illustrated embodiments are the hollow structure 320 with a generally repetitive pattern of the linear segments over its length 374 , the curved segments 378 , the angle 376 and / or the spiral segments 382 show, it should be clear that the hollow structure 320 any suitable variation in position, length, cross-sectional dimension and shape of the linear segments over its length 374 , the curved segments 378 , the angle 376 and / or the spiral segments 382 it has the hollow structure 320 allows to fulfill the function described here.

Each illustrated jacketed core 310 indicates the length 372 which for reasons of clarity is shown separately in dashed lines for each embodiment. Each illustrated jacketed core 310 further defines the end separation distance 370 , A ratio of length 372 to the end separation distance 370 is a measure of a degree of nonlinearity of the sheathed core 310 , and thus a nonlinearity of the hollow structure 320 and the inner core 324 , For example, the end separation distance is 370 in some embodiments where the sheathed core 310 , as in 6 Shown is, at least about 61 cm (24 inches), the length 372 is at least about 75 cm (29.5 inches) and the inner core 324 defines a ratio of a length to an end separation distance of at least about 1.2. In another example, the end separation distance is 370 in the embodiment shown in FIG 7 left, at least about 2.54 cm (1 inch), the length 372 is at least about 9.6 cm (3.8 inches), and the inner core 324 defines a ratio of a length to an end separation distance of at least about 3.8. In another example, the end separation distance is 370 in the embodiment, in the middle of 7 shown at least about 2.54 cm (1 inch) in length 372 is at least about 7.6 cm (3 inches) and the inner core 324 defines a ratio of a length to an end separation distance of at least about 3. In another example, the end separation distance is 370 in the embodiment shown in FIG 7 shown to the right, at least about 2.54 cm (1 inch), the length 372 is at least about 15.2 cm (6 inches) and the inner core 324 defines a ratio of a length to an end separation distance of at least about 6.

As described above, the sheathed core becomes 310 formed by the inner core material 326 inside the hollow structure 320 is removed, leaving the inner core 324 through the inner section 360 the hollow structure 320 is designed to be complementary. Following this is the sheathed core 310 in terms of the mold 300 positioned, and it becomes the mold 300 melted component material 78 added so that the inner core 324 the internal passage 82 inside the component 80 forms. In particular embodiments, use of a similarly non-linear, but not encapsulated inner core (not shown) having ratios of a length to an end separation distance of at least about 1.2, at least about 3, and / or at least about 6, but without, for example to limit it to the inner cores described above 324 represent a relatively high risk in producing a reliably useful component 80 , inside which is the non-linear internal passage 82 is defined, to fail. For example, but not limited to, the stress concentrations introduced by the nonlinearities increase the risk of cracking or fracturing of the unjacketed ceramic core prior to or during core removal from a core mold, formation of (in 3 shown) mold assembly 301 and / or a formation of the component 80 , As discussed above, the hollow structure enhances 320 however, in some embodiments, the inner core 324 structurally essential, so that the sheathed core 310 Advantages associated with connecting the inner core 324 with the mold 300 to the non-linear internal passage 82 while allowing problems related to the breakage sensitivity of the inner core 324 be reduced or eliminated. In modified embodiments, the hollow structure reinforces 320 the inner core 324 structurally not essential.

In specific embodiments, the hollow structure becomes 320 again before removing the intervening inner core material 326 prefabricated, wherein at least partially a suitable additive manufacturing process is used, in which, for example, a CNC machine from the first end 362 to the second end 364 successive layers of the first material 322 separates to the hollow structure 320 to build. More specifically, the CNC machine separates successive layers of the first material 322 off to every next layer, eg the layer illustrated 366 , the hollow structure 320 to build. As described above, forming the hollow structure allows 320 using a suitable additive manufacturing process, forming the nonlinear aspects of the sheathed core 310 However, for example, without wishing to be limited, corresponding angles 376 and / or spiral sections 382 , with a structural complexity, accuracy and / or reproducibility that can not be achieved by other methods.

8th shows a schematic sectional view of six additional embodiments of the sheathed core 310 for use in the (in 3 shown) mold assembly 301 , In each embodiment, the sheathed core is 310 designed so that a cross-sectional circumference of the inner core 324 a selected cross-sectional perimeter of the internal passage 82 corresponds, ie the hollow structure 320 is designed so that the cross-sectional circumference of the inner core 324 inside the hollow structure 320 is arranged, the cross section of the internal passage 82 inside the (in 2 shown) component 80 defines if the component 80 in the mold 300 is formed.

In specific embodiments, a performance of the internal passage becomes 82 increased by a cross-sectional perimeter of at least a portion of the internal passage 82 with respect to a cross-sectional area of at least the portion of the internal passage 82 is increased. As a non-limiting example, the internal pass is 82 adapted to a cooling fluid through the component 80 to conduct, and a heat transfer performance of the internal passage 82 is improved by a cross-section that occupies a wetted perimeter of the internal passageway 82 for a given cross-sectional area of the internal passage 82 increased. A measure of the perimeter area is a ratio of a cross-sectional perimeter squared to the perimeter perimeter area, referred to herein as the "p2A Ratio".

For example, the inner core 324 in the first embodiment, which is in 8th shown on the left, a substantially circular cross-sectional circumference. In correspondence is the inner core 324 designed to have a substantially circular cross-section of the internal passage 82 inside the component 80 and defines a p2A ratio of about 12.6.

In another example, the inner core 324 in the embodiment shown in FIG 8th is shown as the second from the left, a substantially T-shaped cross-sectional circumference. In correspondence is the inner core 324 designed to be a substantially T-shaped cross section of the internal passageway 82 inside the component 80 and defines a p2A ratio of about 28.2.

In another example, the inner core 324 in the embodiment shown in FIG 8th is shown as the third from the left, a substantially H-shaped cross-sectional circumference. In correspondence is the inner core 324 designed to a substantially H-shaped cross section of the internal passage 82 inside the component 80 and defines a p2A ratio of about 44.6.

In another example, the inner core 324 in the embodiment shown in FIG 8th is shown as a fourth from the left, a substantially crescent-shaped cross-sectional circumference. In correspondence is the inner core 324 designed to be a substantially crescent-shaped cross section of the internal passage 82 inside the component 80 and defines a p2A ratio of about 35.5.

In another example, the inner core 324 in the embodiment shown in FIG 8th shown as the fifth from the left, essentially a cross-sectional perimeter of the shape of a five-pointed star. In correspondence is the inner core 324 designed to be substantially a cross-section of the shape of a five-pointed star of the internal passage 82 inside the component 80 and defines a p2A ratio of about 46.8.

In another example, the inner core 324 in the embodiment shown in FIG 8th shown to the right, substantially a cross-sectional perimeter of the shape of a twelve-pointed star. In correspondence is the inner core 324 designed to be substantially a cross-section of the shape of a twelve-pointed star of the internal passage 82 inside the component 80 and defines a p2A ratio of about 89.2.

As described above, the sheathed core becomes 310 formed by the inner core material 326 inside the hollow structure 320 is removed, leaving the inner core 324 through the inner section 360 the hollow structure 320 is designed to be complementary. Following this is the sheathed core 310 in terms of the mold 300 positioned, and it becomes the mold 300 melted component material 78 added so that the inner core 324 the internal passage 82 inside the component 80 forms. In particular embodiments, using (not shown) similar but uncovered inner cores having p2A ratios of at least about 40 and / or at least about 80, for example, but not limited to, would require the inner cores described above 324 , represent a relatively high risk, with a reliable production of a usable component 80 that the internal passage 82 having a relatively high p2A ratio defined therein to fail. For example, however without being limited thereto, the stress concentrations introduced by the complicated shape of the cross-sectional periphery increase the risk of cracking or breaking of the unjacketed ceramic core prior to or during removal of the core from a core mold, forming the (in 3 shown) mold assembly 301 and / or a formation of the component 80 , As discussed above, the hollow structure enhances 320 however, in some embodiments, the inner core 324 structurally essential, so that the sheathed core 310 Advantages associated with connecting the inner core 324 with the mold 300 to the internal passage 82 while having a relatively high p2A ratio, problems associated with the breakage sensitivity of the inner core 324 be reduced or eliminated. In modified embodiments, the hollow structure reinforces 320 the inner core 324 structurally not essential.

In specific embodiments, the hollow structure becomes 320 again before removing the intervening inner core material 326 prefabricated, wherein at least partially a suitable additive manufacturing process is used, in which, for example, a CNC machine from the first end 362 to the (in 7 shown) second end 364 successive layers of the first material 322 separates to the hollow structure 320 to build. More specifically, the CNC machine separates successive layers of the first material 322 off to every next layer of the hollow structure 320 to build. As described above, forming the hollow structure allows 320 forming a complicated cross-sectional periphery of the sheathed core using a suitable additive manufacturing process 310 , with a structural complexity, accuracy and / or reproducibility that can not be achieved by other methods. In addition, forming the hollow structure allows 320 forming the hollow structure using a suitable additive manufacturing process 320 with a selected nonlinear shape along the length of the hollow structure 320 as described above and / or complicated cross-sectional circumferences along portions of the hollow structure 320 in a single molding process with little or no interference between the separate design parameters.

9 shows in a schematic perspective view a portion of another exemplary component 80 that the internal passage 82 with several passage wall features 98 having. By way of example, but not limited to, the passageway features are 98 Turbulators that improve the heat transfer capability of a cooling fluid, the internal passage 82 during operation of the rotating machine 10 is supplied. 10 shows in a schematic perspective view another exemplary coated core 310 for use in the mold assembly 301 to the component 80 to form the passageway wall features 98 has, as in 9 shown. In particular, a section of the hollow structure 320 in the view of 10 cut off to features of the inner core 324 to illustrate.

With reference to 9 and 10 is the internal passage 82 through an inner wall 100 the component 80 defined, and the passage wall features 98 extend from the inner wall 100 generally toward a center of the internal passageway 82 radially inward. As discussed above, the shape of the inner core defines 324 the shape of the internal passage 82 , In specific embodiments, has an outer surface 332 of the inner core 324 at least one recessed feature 334 which has a shape corresponding to a shape of at least one passage wall feature 98 is complementary. Consequently, define the outer surface 332 and the recessed features 334 of the inner core 324 in some embodiments, a shape of the inner wall 100 and the passageway wall features 98 of the internal passage 82 ,

For example, the recessed features 334 in some embodiments a plurality of grooves 350 on that in the outer surface 332 are formed, so that when the molten component material 78 into the mold cavity 304 is introduced, the sheathed core 310 surrounds, and the first material 322 into the molten component material 78 is absorbed, that molten component material 78 the several grooves 350 crowded. The cooled component material 78 in the grooves 350 forms the several passage wall features 98 after the inner core 324 , eg, but not limited to being removed using a chemical leaching process. Additionally or alternatively, the intact portion of the inner portion defines 360 that is against the at least one recessed feature 334 coupled, the at least one internal passage wall feature 98 to a degree to which a section of the inner section 360 the hollow structure 320 adjacent to the inner core 324 remains intact after the molten component material 78 into the mold cavity 304 introduced and cooled. For example, every groove 350 with a groove depth 336 and a groove width 338 defined, and any corresponding passage wall feature 98 is with a feature height 102 which are substantially equal to the groove depth 336 is, and a feature width 104 formed, which is substantially equal to the groove width 338 is.

11 shows in a schematic perspective view a portion of another exemplary component 80 that the internal passage 82 having a contoured cross section having a relatively high p2A ratio. 12 shows in a schematic perspective view another exemplary coated core 310 for use in the mold assembly 301 to the component 80 to form the internal passage 82 , as in 11 shown. In particular, a section of the hollow structure 320 in the view 12 cut off to features of the inner core 324 to illustrate.

With reference to 11 and 12 is the component 80 in the embodiment, either the rotor blade 70 or the stator vane 72 , and the internal passage 82 is in the component 80 near the trailing edge 86 Are defined. More special is the internal passage 82 through the inner wall 100 the component 80 defined to have a contoured cross-sectional perimeter of a tapered geometry of the trailing edge 86 equivalent. The passage wall features 98 are along opposite elongated edges 110 of the internal passage 82 formed to act as turbulators, and they extend from the inner wall 100 off toward a center of the internal passageway 82 inside. Although the passage wall features 98 are illustrated as a repeating pattern of elongated ridges, all transverse to an axial direction of the internal passage 82 It should be understood that the passage wall features 98 in modified embodiments, they may have any suitable shapes, orientations and / or patterns that suit the internal passageway 82 allow it to fulfill its intended function.

As discussed above, define the shape of the outer surface 332 and the recessed features 334 of the inner core 324 the shape of the inner wall 100 and the passageway wall features 98 of the internal passage 82 , The inner core is more specific 324 an elongated, tapered cross-sectional perimeter on the contoured cross-section of the internal passageway 82 equivalent. In the embodiment, the recessed features 334 as elongated recesses 354 in opposite oblong sides 346 the outer surface 332 define and have a shape that, as described above, to a shape of the passage wall features 98 is complementary. The inner section 360 the hollow structure 320 is designed to the selected shape of the outer surface 332 of the inner core 324 and thus the selected shape of the passage wall features 98 define.

With reference to 9 - 12 is the inner section 360 the hollow structure 320 preformed in some embodiments to prevent filling of the hollow structure 320 with the inner core material 326 a selected shape of the outer surface 332 and the recessed features 334 of the inner core 324 and thus define a selected shape of the passageway wall features 98 define. For example, the hollow structure 320 Crimped at several points to several notches 340 to define, and every notch 340 causes the inner section 360 the hollow structure 320 a corresponding omitted feature 334 forms when the hollow structure 320 with the inner core material 326 is filled. A depth 342 every notch 340 defined in cooperation with the wall thickness 328 the groove depth 336 the corresponding groove 350 , In another example, the hollow structure is 320 Crimped at several points to several notches 340 to define, and every notch 340 causes the inner section 360 a corresponding recess 354 forms when the hollow structure 320 with the inner core material 326 is filled.

In another example, the hollow structure is 320 again prefabricated, at least in part, using a suitable additive manufacturing process in which, for example, a CNC machine from the (in 7 shown) first end 362 to the second end 364 successive layers of the first material 322 separates to the hollow structure 320 to build. More specifically, the CNC machine separates successive layers of the first material 322 off to every next layer of the hollow structure 320 including subsequent layers of the inner section 360 which is designed around the passage wall features 98 define. As described above, forming the hollow structure allows 320 using a suitable additive manufacturing process, forming the inner portion 360 with a structural complexity, accuracy and / or reproducibility that can not be achieved by other methods. In addition, forming the hollow structure allows 320 using a suitable additive manufacturing process, the hollow structure 320 with the inner section 360 formed to the passageway wall features 98 , a selected nonlinear shape along the length of the hollow structure 320 and / or complicated cross-sectional circumferences along sections of the hollow structure 320 as described above, with reduced or no interference between the separate design parameters in a single molding operation.

In some embodiments, forming the hollow structure reduces 320 to the selected shape of the outer surface 332 of the inner core 324 before filling the hollow structure 320 to define possible problems associated with shaping the outer surface 332 after the inner core 324 is shaped. For example, the inner core material 326 a relatively brittle ceramic material, so that by a direct machining or other treatment of the outer surface 332 for shaping the recessed features 334 a fairly high risk of breakage, tearing and / or other damage to the inner core 324 would be caused. Thus, the sheathed core allows 310 a shape of the inner core 324 so that the passage wall features 98 integral with the internal passage 82 be formed while problems related to the breakage sensitivity of the inner core 324 be reduced or eliminated.

13 shows in a schematic perspective view a portion of another exemplary component 80 that the internal passage 82 with a further number of passage wall features 98 having. 14 FIG. 12 shows a schematic perspective view of yet another exemplary sheathed core. FIG 310 for use in the mold assembly 301 to the component 80 with the passage wall features 98 , as in 13 shown to form. In the illustrated embodiment, each recessed feature is 334 a recess 352 that span less than the entire circumference of the inner core 324 extends so that each corresponding passageway feature 98 around less than the entire circumference of the internal passage 82 extends.

In specific embodiments, the sheathed core is 310 edited to a selected shape of the outer surface 332 and the recessed features 334 of the inner core 324 and thus to define a selected shape of the passageway wall features 98 after forming the inner core 324 in the sheathed core 310 define. For example, the sheathed core becomes 310 at the beginning without the recessed features 334 formed and then processed by a plurality of machining operations, such as, but not limited to, a machining process, at any location in the inner core 324 recesses 352 to build. In some such embodiments, a portion of the hollow structure becomes 320 near at least one recessed feature 334 removed, leaving in the hollow structure 320 an opening 348 arises to gain access to the outside surface 332 of the inner core 324 to allow for a machining. For example, in the embodiment, in a machining process, recesses are made 352 in the outer surface 332 Sections of the hollow structure 320 near the recesses 352 removed by machining.

In some embodiments, processing of the sheathed core reduces 310 to the selected shape of the outer surface 332 of the inner core 324 after forming the inner core 324 inside the sheathed core 310 to define possible problems related to filling the hollow structure 320 , in the 6 shown) prefabricated notches 340 having, with the inner core material 326 For example, the problem of ensuring that the inner core material 326 every notch 340 Fills around a figure appropriately. In addition, in some such embodiments, a shape of the recessed features 334 selected to address the above-described potential problems associated with the machining of the inner core material 326 to reduce. For example, the machining of the recesses reduces 352 that only partially surround the circumference of the inner core 324 a risk of breakage, cracking and / or other damage to the inner core 324 , Additionally or alternatively, the hollow structure improves 320 In some such embodiments, structural strength of the inner core 324 during the machining operations on the sheathed core 310 what the risk of breakage, cracking and / or other damage to the inner core 324 further reduced. Thus, the sheathed core simplifies 310 the shaping of the inner core 324 again, so that the passage wall features 98 integral with the internal passage 82 be formed while problems related to the breakage sensitivity of the inner core 324 be reduced or eliminated.

With reference to 9 - 14 In modified embodiments, other forms of the recessed features 334 used to shape the outside surface 332 although the illustrated embodiments have recessed features 334 show in the outer surface 332 exclusively as the grooves 350 and the recesses 352 and 354 are formed to a shape of the passage wall features 98 define. For example, but not limited to, at least one recessed feature extends in some embodiments (not shown) 334 at least in part in the longitudinal direction and / or obliquely along the inner core 324 , In another example, but without wishing to be limited thereto, in some embodiments (not shown), at least one recessed feature 334 a crater in the outer surface 332 is defined to be a corresponding one Passage wall feature 98 to form, which has a stud shape. In another example, but without wishing to be limited thereto, in some embodiments (not shown), at least one recessed feature is included 334 in the inner core 324 defined to define at least one passage wall feature as a sharp-edged bead, a truncated-edged bead, a drawn groove, or a louver structure. In modified embodiments, any suitable shape of the inner core will be used 324 used to a corresponding shape of the passage wall features 98 to define it's internal passage 82 allowed to fulfill its intended function. Although the illustrated embodiments are each embodiment of the inner core 324 as the recessed features 334 show a substantially identical repetitive shape, it should be further understood that the inner core 324 any suitable combination of differently designed recessed features 334 that is the inner core 324 allows to fulfill the function described here.

An exemplary procedure 1500 for molding a component, for example the component 80 having an internal passage formed therein like the internal passage 82 is in a flowchart in FIG 15 and 16 illustrated. Also referring to 1 - 14 includes the exemplary method 1500 a positioning 1502 a sheathed core, eg the sheathed core 310 , in relation to a casting mold, eg the casting mold 300 , The mold defines therein a cavity, eg the mold cavity 304 , The sheathed core has a hollow structure, eg the hollow structure 320 that is at least partially formed by an additive manufacturing process. The sheathed core further includes an inner core, eg, the inner core 324 , which is located inside the hollow structure. Further, the method includes 1500 an introduction 1504 a component material, eg the component material 78 , in a molten state in the cavity and a cooling 1506 of the component material in the cavity to form the component. The inner core is positioned to define the internal passageway in the component.

In particular embodiments, the step of positioning includes 1502 positioning of the sheathed core 1508 of the sheathed core having the hollow structure formed using at least one direct metal laser melt (DMLM) method, direct metal laser sintering (DMLS) method and / or selective laser sintering (SLS), Method is formed. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1510 of the sheathed core having the hollow structure made of a first material, eg the first material 322 , which is at least partially absorbable by at least one nickel-base superalloy, a cobalt-based superalloy, an iron-based alloy, a titanium-based alloy, and / or a platinum-based superalloy. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1512 of the sheathed core having the inner core formed of at least one of silica, alumina and mullite.

In some embodiments, the positioning step includes 1502 positioning of the sheathed core 1514 of the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 25. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1516 of the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 60. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1518 of the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 70. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1520 of the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 80.

In particular embodiments, the step of positioning includes 1502 positioning of the sheathed core 1522 of the sheathed core having the inner core defining a ratio of a length to an end separation distance of at least about 1.2. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1524 of the sheathed core having the inner core defining a ratio of a length to an end separation distance of at least about 3. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1526 of the sheathed core having the inner core defining a ratio of a length to an end separation distance of at least about 6.

In some embodiments, the positioning step includes 1502 positioning of the sheathed core 1528 the sheathed core having at least a portion of the inner core, defining a cross-section, wherein the cross-section defines a ratio of a perimeter squared to an area of at least about 40. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1530 of the sheathed core having at least a portion of the inner core defining a cross section, the cross section defining a ratio of a perimeter squared to an area of at least about 80.

In particular embodiments, the step of positioning includes 1502 positioning of the sheathed core 1532 of the sheathed core having the hollow structure defining a plurality of substantially linear segments, eg, the linear segments 374 which are connected in series. Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1534 of the sheathed core having the hollow structure defining a plurality of substantially linear segments, eg, the linear segments 374 which are connected in series with a plurality of curved segments, eg with the curved segments 378 , Additionally or alternatively, the step of positioning includes 1502 positioning of the sheathed core 1536 the sheathed core having at least a portion of the hollow structure defining a substantially helical shape, eg, the helical shape 382 ,

 The sheathed core described above provides a low cost method of making at least some components having internal passages formed therein while reducing or eliminating core-related fracture sensitivity problems. In particular, the sheathed core has the inner core positioned inside the mold cavity to define the position of the internal passage in the component, and also has the hollow structure inside which the inner core is disposed. The hollow structure is at least partially formed by an additive manufacturing process. In particular, but without intending to be limited thereto, the encased core and methods described herein, using a single integrated molding process, enable reliable and repeatable formation of internal vias having at least one and possibly all three properties of a large ratio of length to diameter define substantially non-linear shape and a complicated cross-sectional circumference. In addition, the hollow structure is particularly formed of a material that is at least partially absorbable by the molten component material that is introduced into the mold cavity to form the component. Thus, the use of the hollow structure does not affect the structural or performance characteristics of the component and does not hinder the subsequent removal of the inner core material from the component to form the internal passageway.

 In addition, the sheathed core described herein enables a low cost and high accuracy method of integrally forming via wall features in the internal passageway. Specifically, in some embodiments, the hollow structure enhances the inner core such that a risk of tearing of the inner core near stress concentrations associated with a complementary geometry of feature-shaping the inner core is reduced. Additionally or alternatively, the ability of preforming the hollow structure to define the inner core allows for adding complimentary features to the inner core without machining the inner core so as to avoid the risk of tearing or damage to the core.

 An exemplary technical effect of the methods, systems, and devices described herein includes at least one of the following: (a) reducing or eliminating fracture hazards associated with the formation, handling, transport, and / or storage of the core used in forming a component having an internal passage formed therein; (b) reliable and repeatable molding of components having internal vias formed using a single integral process to form at least one and possibly all three properties of a large ratio of length to diameter, substantially non-linear shape, and complicated cross-sectional perimeter exhibit; and (c) reducing or eliminating breakage problems associated with features of the core that define via wall features complementary in the component.

 In the above, embodiments of coated cores are described in detail. The sheathed cores and the methods and systems using such sheathed cores are not limited to the specific embodiments presented herein, but portions of systems and / or steps of the methods may be utilized independently and separately from other components and / or steps described herein , For example, the embodiments may be used in conjunction with many other applications that are currently configured to use cores in mold assemblies.

Although particular features of different embodiments of the description may be shown in some drawings and not in others, this is for convenience of illustration only. In accordance with the principles of the description, each feature of a drawing may be referenced and / or claimed in combination with any feature of any of the remaining drawings.

 This written description uses examples to describe the embodiments that include the best mode and also to enable any person skilled in the art to make the embodiments, including making and using any devices and systems, and to carry out any associated methods. The patentable scope of the description is defined by the claims, and may include other examples of skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that differ only slightly from the literal language of the claims.

Created is a procedure 1500 for molding a component 80 having an internal passage formed therein 82 having. The method includes positioning 1502 a sheathed core 310 in terms of a mold 300 , The sheathed core has a hollow structure 320 at least partially formed by an additive manufacturing process, and an inner core 324 placed inside the hollow structure. The method further comprises an introduction 1504 a component material 78 in a molten state into a cavity 304 the mold and a cooling 1506 of the component material in the cavity to form the component. The inner core is positioned to define the internal passageway in the component. LIST OF REFERENCE NUMBERS: 10 rotary engine 12 suction 14 compressor section 16 combustor section 18 turbine section 20 outlet 22 rotor shaft 24 burner 36 casing 40 Compressor blades 42 Verdichterstatorleitschaufeln 70 blade 72 Turbinenstatorleitschaufeln 74 pressure side 76 suction 78 Molten component material 80 component 82 Internal passage 84 leading edge 86 trailing edge 88 foot 89 axis 90 Opposite top end 92 Constant distance value 94 Constant distance value 96 Blade length 98 Passage wall feature 100 Inner wall (one component) 102 feature height 104 feature width 110 Extended edges 300 mold 301 Mold arrangement 302 Inner wall (the mold) 304 Mold cavity 306. Mold material 310 Sheathed core 312 tip portion 314 tip portion 315 Area 316 foot section 318 foot section 320 Hollow structure 322 First material 324 Inner core 326 Inner core material 328 Wall thickness 330 Characteristic width 332 outer surface 334 Outsourced feature 336 groove depth 338 groove width 340 notch 342 depth 346 Extended pages 348 opening 350 groove 352 recess 354 recess 360 Inner section 362 First end 364 Second end 366 layer 367 layer 368 layer 370 End separation distance 372 length 374 Linear segments 376 Corresponding angles 378 Curved segments 380 Outer wall 382 Spiral shape 1500 method 1502 Step of positioning 1504 bring 1506 Cool 1508 positioning 1510 positioning 1512 positioning 1514 positioning 1516 positioning 1518 positioning 1520 positioning 1522 positioning 1524 positioning 1526 positioning 1528 positioning 1530 positioning 1532 positioning 1534 positioning 1536 positioning

Claims (10)

Procedure ( 1500 ) for molding a component ( 80 ) having an internal passage formed therein ( 82 ), the method comprising: positioning ( 1502 ) of a sheathed core ( 310 ) with respect to a casting mold ( 300 ), wherein the sheathed core comprises: a hollow structure ( 320 ) formed at least in part by an additive manufacturing process; and an inner core ( 324 ) disposed within the hollow structure; Introduction ( 1504 ) of a component material ( 78 ) in a molten state into a cavity ( 304 ) of the mold; and cooling ( 1506 ) of the component material in the cavity to form the component, the inner core forming the internal passage in the component. Method according to claim 1, wherein the positioning ( 1502 ) of the sheathed core positioning ( 1508 ) of the sheathed core having the hollow structure formed using a direct metal laser melting method (DMLM method) and / or a direct metal laser sintering method (DMLS method) and / or a selective laser sintering method (SLS method). Method according to claim 1 or 2, wherein the positioning ( 1502 ) of the sheathed core positioning ( 1514 ) of the sheathed core having the inner core defining a ratio of a length to a diameter of at least about 25. Method according to one of the preceding claims, wherein the positioning ( 1502 ) of the sheathed core positioning ( 1522 ) of the sheathed core having the inner core defining a ratio of a length to an end separation distance of at least about 1.2. Method according to one of the preceding claims, wherein the positioning ( 1502 ) of the sheathed core positioning ( 1528 ) of the sheathed core having at least a portion of the inner core defining a cross section, the cross section defining a ratio of a perimeter squared to an area of at least about 40. Casting arrangement ( 301 ) for use in molding a component ( 80 ) having an internal passage formed therein ( 82 ), wherein the mold assembly includes: a mold ( 300 ) having therein a mold cavity ( 304 ) forms; and a sheathed core ( 310 ) positioned with respect to the mold, the encased core comprising: a hollow structure ( 320 ) formed at least in part by an additive manufacturing process; and an inner core ( 324 ) positioned in the hollow structure and positioned to define the internal passage in the component when a component material ( 78 ) is introduced into the cavity in a molten state and cooled to form the component. A mold assembly according to claim 6, wherein the hollow structure is made of a first material ( 322 ) which is at least partially absorbable by at least one nickel-base superalloy and / or a cobalt-based superalloy and / or an iron-based alloy and / or a titanium-based alloy and / or a platinum-based superalloy. The mold assembly of claim 6 or 7, wherein the inner core defines a ratio of a length to a diameter of at least about 25. The mold assembly of any one of claims 6 to 8, wherein the inner core defines a ratio of a length to an end separation distance of at least about 1.2. The mold assembly of any one of claims 6 to 9, wherein at least a portion of the inner core defines a cross-section, the cross-section defining a ratio of a perimeter squared to an area of at least about 40.

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